Baotian BT49QT-3 Service manual

r
te
C
en
pa
rts
BT50QT-9&BT49QT-3
w
w
w
.a
si
am
ot
or
.s
e
Ba
ot
ia
n
Eu
ro
pe
an
Sp
ar
e
SERVICE MANUAL
JIANGMEN SINO-HONGKONG BAOTIAN MOTORCYCLE INDUSTRIAL CO., LTD
CONTENTS
CHAPTER ONE
MAINTENANCE OF THE MOTORCYCLE
1
Ⅱ.
PERIODIC MAINTENANCE SCHEDULE AND MAINTENANCE LOCATIONS
1
Ⅲ.
MAINTENANCE SPECIFICATIONS
r
Ⅰ. ITEMS OF MAINTENANCE
te
4
C
en
Ⅳ. THROTTLE ACTUATION INSPECTION
Ⅴ. AIR FILTER INSPECTION AND CLEANING
5
6
REAR BRAKE FRICITION LINING INSPECTION
Ⅶ.
BRAKE SYSTEM INSPECTION, ADJUSTMENT AND REPLACEMENT
7
Ⅷ.
FRONT AND REAR SHOCK ABSORBER INSPECTION
8
Ⅸ.
FRONT WHEEL AND REAR WHEEL INSPECTION
e
ar
6
9
10
MAINTENANCE INFORMATION
an
CHAPTER TWO
Sp
Ⅹ. STEERING STEM INSPECTION
pa
rts
Ⅵ.
FRAME NUMBER AND ENGINE NUMBER LOCATION
11
Ⅱ.
PRECAUTIONS IN OPERATION
11
Ⅲ.
SPECIFIED TORQUES
Eu
ro
CHAPTER THREE
pe
Ⅰ.
12
BODY TROUBLESHOOTING
14
n
SECTION ONE BODY COMMON TROUBLES AND TROUBLE DETECTION
ia
SECTION TWO DETAILED DESCRIPTIONS OF BODY PARTS TROUBLES
FRONT WHEEL SERVICE
17
Ⅱ.
FRONT BRAKE SERVICE ( DISK BRAKE )
19
Ⅲ.
FRONT SHOCK ABSORBER SERVICE
21
Ⅳ.
FRONT FORK SERVICE
22
Ⅴ. HANDLEBAR SERVICE
24
Ⅵ.
25
ot
or
.s
e
Ba
ot
Ⅰ.
si
am
REAR WHEEL SERVICE
REAR BRAKE SERVICE
26
Ⅷ.
REAR SHOCK ABSORBER SERVICE
28
w
w
w
.a
Ⅶ.
CHAPTER ONE MAINTENANCE OF THE MOTORCYCLE
C
en
te
r
Ⅰ. ITEMS OF MAINTENANCE
When the motorcycle is used, loosening of parts and mechanical wear inevitably occur to
varied extents. Neglect of timely maintenance not only reduces its mechanical function,
economic performance, stability and durability, but also threatens the safety of the motorcycle
and the rider. Correct and timely maintenance of the motorcycle is a must. Items of maintenance
refer to the parts and positions for maintenance. Different items of maintenance are effected at
different intervals and in different manners.
1. Running-in Maintenance
w
w
w
.a
si
am
ot
or
.s
e
Ba
ot
ia
n
Eu
ro
pe
an
Sp
ar
e
pa
rts
This is the maintenance at the end of the first 1000km and is an all-round inspection of the
motorcycle. A newly-bought motorcycle or a motorcycle fresh from an overhaul might be
severely overheated as a result of severe friction between the moving parts which might be
imperfect in finishing or fitting. Neglect in use might lead to damage of the friction surfaces and
might threaten the performance, and the service life, of the motorcycle. Please observe the
following points:
z Restrict the speed in speed range specified in the instruction manual.
z Restrict the load to 2/3 of the maximum load and ride in fairly good road conditions.
z Restrict the length of riding time to avoid long-time running of the engine.
z Replace engine oil at short intervals so that metal chips caused in the running-in period
can be discharged. It is recommended to replace engine oil for 3 times during the
running-in period.
2. Routine Maintenance
Routine maintenance is the basis of all kinds of maintenances. It refers to the daily
maintenance, including cleaning, inspection and common troubleshooting.
3. Periodic Maintenance
This maintenance is to restore normal performance of the motorcycle. The maintenance is
classified into first-grade periodic technical maintenance and second-grade periodic technical
maintenance (also known as items of maintenance) according to different mileages. Generally
speaking, a first-grade maintenance is effected after the initial 4000km and a second-grade
maintenance is effected every 8000km. As the service time extends, maintenance intervals
should be shortened accordingly.
Ⅱ. PERIODIC MAINTENANCE SCHEDULE AND MAINTENANCE LOCATIONS
After a period of use (one day, one month or half a year, for example) or a certain mileage
(1000km, 4000km, 8000km, for example), an all-round maintenance operation should be
effected, including comprehensive inspection, adjustment, tightening, lubrication, cleaning or
replacement. The specific regulation made according to time intervals or mileages is known as
maintenance interval. The motorcycle maintenance schedule is as follows.
1
1. Maintenance Schedule
Maintenance Schedule
time
Mileage 1000km
item
2000
3000
4000
5000
6000
7000
8000
9000
10000
11000
R
R
R
R
R
R
R
R
R
R
Engine oil
C
R
C
en
300km
te
New R
Engine oil
12000
r
1000
C
pa
rts
strainer
Gasoline
R
strainer
New R
Note 4
R
A
I
Note 3,
I
R
4
Brake system
I
I
I
n
Drive belt
Ba
ot
ia
Suspension
Tire
Steering rod
I
I
I
R
I
I
I
I
I
I
I
I
I
I
ot
or
.s
e
I
I
I
si
am
C
cam
w
.a
Notes:
1. I: Inspect and when necessary, clean, lubricate, supplement, modify or replace;
A: adjust; C: clean; R: replace; T: tighten.
2. Effect periodic maintenance according to the instructions in the user’s manual.
3. When the mileage exceeds the range specified in the schedule, repeat the maintenance.
4. In dusty or rainy conditions, inspection and replacement should be effected earlier.
5. In heavy load, long distance or rainy conditions, replacement should be effected earlier.
w
w
I
I
I
Rear brake
C
I
I
bearing
bolts of parts
I
Clean every 3000km, replace when necessary
Eu
ro
Spark plug
Screws and
A
pe
Air filter
A
an
Carburetor
Sp
A
ar
300km
Throttle play
R
e
Gear oil
2
2. Maintenance locations
Front shock absorber
Oil tank
¨ damage,loosening©
£
¨ brake oil level©
£
£ £
Eu
ro
pe
an
Sp
ar
e
pa
rts
C
en
te
r
Spark plug
Throttle grip
¨ damage,contamination©
£
££
¨ actuation,play £
©
Rear tire
Rear rim
¨ wear,damage,tire pressure £
£
©
¨ damage,oscillation©
£
£
n
Rear brake rod
¨ free play£
£
©
Rear shock absorber
Air filter
¨£ damage,loosening©
£ £
¨ contamination©
£
w
w
w
.a
si
am
ot
or
.s
e
Ba
ot
ia
Headlight
¨ beam adjustment©
£
£
Front rim
Front tire
¨ damage,oscillation©
£
££
¨ wear,damage,tire pressure£
©
Front brake disc
Front brake caliper
¨£ damage,wear ©
£ £
¨ wear of friction lining£
©
Rear brake
gearcase
¨£ wear of brake drum,
¨ engine oil quantity,
£
damage,wear of friction lining£
© oil replacement £
©
3
w
w
w
.a
si
am
ot
or
.s
e
Ba
ot
ia
n
Eu
ro
pe
an
Sp
ar
e
pa
rts
C
en
te
r
Ⅲ. MAINTENANCE SPECIFICATIONS
The basic methods of motorcycle maintenance include inspection, adjustment, tightening,
lubrication, cleaning, supplementing and replacement, which constitute the main elements of
maintenance.
1. Inspection
Inspection refers to basic inspecting operations in accordance with items and
requirements specified in the user’s manual, including inspection with instruments or
with eyes for abnormalities in machine parts, directly comparing related data and
aligning with tools and gauges.
2. Adjustment
Adjustment refers to inspection-based adjustment and rectification of some specified
machine parts, including adjustment of machine part plays and rectification of
misfittings and deformations so as to restore correct positions, forms and plays.
3. Tightening
Tightening refers tightening of bolts, screws and nuts of machine parts with tools so as
to avoid loosening of machine parts and to obtain specified tightening torques.
4. Cleaning
Cleaning is needed by machine parts and positions which call for cleanliness and
tidiness. Cleaning operations include all the means and measures taken to remove dust,
contamination, metal chips, oily stains and carbon deposits that might lead to pipe
clogging or reduction in motorcycle performance. Cleaning measures are washing,
carbon deposit removing, rubbing, cleaning and clearing.
5. Lubrication
In order to facilitate smooth and easy running of moving machine parts, including
swinging parts, reciprocating parts, sliding parts and vibrating parts, to reduce scuffing,
abrasion, deformation and to reduce friction, it is necessary to coat or spray these parts
with a lubricant. Different lubricants and lubricating methods are required for different
machine parts with different functions. Application of lubricants to machine parts is
known as lubrication.
6. Replenishing, supplement and replacement
These operations refer to addition of oil, lubricants, cooling water, electrolyte, fuel and
replacement of damaged parts with new ones and replacement of denatured oils with
new oils.
4
IV. THROTTLE ACTUATION INSPECTION
free travel:2-6mm
adjusting nut
an
Sp
ar
tightening nut
Ba
ot
ia
n
Eu
ro
pe
The main adjusting position is beside the
carburetor.
Remove rear store case cover.
Adjust by loosening the fastening nut and
turning the adjusting nut.
e
pa
rts
C
en
te
r
Inspect throttle grip for easy and smooth
movement.
Inspect throttle free travel.
Free travel: 2-6mm
si
am
ot
or
.s
e
Fine adjustment is effected on the side of
the throttle grip.
Effected adjustment is by removing the dust
cover, loosening the tightening nut and turning
the adjusting nut.
w
w
w
.a
tightening nut
dust cover
adjusting nut
5
C
en
te
r
Ⅴ. AIR FILTER INSPECTION AND CLEANING
After a certain mileage, dust and impurities will gather in air filter case and strainer, which
will clog strainer pores and reduce inlet of air and thus lead to excessive concentration of mixed
gas and reduce the performance of engine. That’s why the strainer must be cleaned every
2000-3000km and in dusty or rainy conditions strainer must be cleaned or replaced earlier.
pa
rts
Remove 5 tightening bolts of air filter.
Remove strainer cover.
Take out the foam strainer.
Ba
ot
an
ia
n
Eu
ro
pe
Immerse foam strainer in gasoline and wash
it to remove dust and impurities by gripping and
pressing.
Press gasoline out of the foam.
Soak the cleaned foam with engine oil, press
out or throw out engine oil to leave it moist with
oil.
Mount.
bolt
Sp
ar
e
air filter
cleaning
gripping
ot
or
.s
e
VI. REAR BRAKE FRICTION LINING INSPECTION
w
w
w
.a
si
am
If the arrow on brake swing arm is aligned
with the scotch on gear case when brake lever is
drawn to the stopping position, friction linings
must be replaced with new ones.
arrow
6
scotch
gasoline soaking
gripping
VII. BRAKE SYSTEM INSPECTION, ADJUSTMENT AND REPLACEMENT
1. Front brake (disk brake)
C
en
te
r
Remove the bolts linking brake caliper and
front shock absorber;
Remove brake caliper.
brake caliper
e
ar
Sp
an
brake caliper
brake block
n
Eu
ro
pe
* Do not pull brake lever when brake caliper is
removed so as to prevent jamming of brake
block.
If brake block is jammed, pry it with
screwdriver and push piston back into caliper.
pa
rts
bolts
front shock absorber
ot
or
.s
e
Ba
ot
ia
Brake Block Replacement:
Brake block must be replaced when it is worn
to the limit of use.
* It is not necessary to remove brake oil pipe
when replacing brake block.
* Brake block must be replaced as a set.
w
w
w
.a
si
am
Remove the brake block pin by means of a
hexagon wrench.
Return brake caliper left part counter-clockwise,
remove old brake block and mount new brake
block.
Effect mounting in an order reversed to that of
dismounting.
7
brake block pin
brake caliper left part
Brake Disc Inspection:
Inspect brake disc thickness.
Limit of use: 3.0mm
2. Rear Brake
rear brake lever
pe
Ba
ot
ia
n
Eu
ro
Turn adjusting nut to effect adjustment
when free travel exceeds limit.
an
Sp
ar
e
pa
rts
Inspect rear brake lever free travel.
Free travel: 10-20mm
C
en
te
r
Inspect brake disc angularity.
Limit of use: 0.3mm
ot
or
.s
e
adjusting nut
VIII. FRONT AND REAR SHOCK ABSORBER INSPECTION
si
am
1. Front Shock Absorber
front brake lever
w
w
w
.a
Tighten front brake lever, press front shock
absorber up and down and inspect actuation.
Inspect front shock absorber to see if there is
leakage of oil and if there is damage or loosening.
8
C
en
te
r
2. Rear Shock Absorber
Press rear shock absorber to inspect
actuation. Inspect rear shock absorber to see if
there is oil leakage and if there is damage or
loosening in machine parts.
Lift rear wheel, press rear wheel right and
left to inspect if engine suspension lug buffer
bush is loose.
pa
rts
IX. FRONT WHEEL AND REAR WHEEL INSPECTION
pe
an
Sp
ar
e
Wheel Rim Inspection:
Inspect wheel rim, remove rust stains and rubber chips.
Deformation and fissures are causes of air leakage. Do not use wheel rims in the following
cases:
Bruise of wheel rim face contacting tire bead ring exceeds 0.5mm in depth and 1.0mm in
width.
w
w
w
.a
si
am
ot
or
.s
e
Ba
ot
ia
n
Eu
ro
Tire Inspection:
Inspect if there is fissure or iron nail in the tire.
In one of the following conditions, tires must be replaced instead of repair.
z Puncture of tire by a foreigner matter 6mm in diameter or tire fissure.
z Layered tire.
z Chunking of tread
z Damaged tire bead
z Broken tire bead or other tire bead damages
z Broken tire cord
z Damage due to forced dismounting
z Fissure extending to frame
z Abnormal inner lining
z Tire groove wear: front wheel < 0.8mm, rear wheel < 0.8mm.
z Punctured or otherwise damaged tire flank
Inspect tire pressure by means of a tire pressure gauge
* Tire pressure should be inspected when the motorcycle is in a cold state.
Specified pressure
Unit: kPa
Front wheel
200
Rear wheel
225
9
Inspect if front wheel nut is loose.
Inspect if rear wheel nut is loose.
If loose, tighten them to specified torques.
r
Tire Specifications:
Front wheel 3.0-10/3.50-10
Rear wheel 3.0-10/3.50-10
pa
rts
C
en
te
front axle nut
Eu
ro
X. STEERING STEM INSPECTION
pe
an
Sp
ar
e
Torques: front wheel nut 60N·m
rear wheel nut 120N·m
w
w
w
.a
si
am
ot
or
.s
e
Ba
ot
ia
n
Swing handlebar right and left to see if there
is interference such as wire or other things.
Turn front wheel to see that handlebar is easy
in operation.
In case of any difficulty in operation, inspect
steering stem bearing assembly.
10
rear axle nut
CHAPTER TWO
MAINTENANCE INFORMATION
pa
rts
C
en
te
r
I. FRAME NUMBER AND ENGINE NUMBER LOCATION
frame number
ar
e
engine number
w
w
w
.a
si
am
ot
or
.s
e
Ba
ot
ia
n
Eu
ro
pe
an
Sp
II. PRECAUTIONS IN OPERATION
z Removed washers, 0-rings, elastic retaining rings and split pins must be replaced with
new ones.
z When mounting bolts, nuts and screws, proceed from trial tightening, from larger
diameters to smaller diameters and inner ones to outer ones in a diagonally order. Tighten
them to specific torques.
z Parts and greases must be those made by our factory or recommended by our factory.
z Special operations must be effected with special tools or specified universal tools.
z Removed parts must be rubbed or cleaned before they are inspected or measured. They
must be coated on the sliding faces before mounting.
z They must be greased at the specified positions with designated or equivalent greases.
z Parts must be tightened and their performances inspected at their positions when
mounted.
z The battery’s negative terminal must be disconnected before operation.
Make sure that tools such as wrenches are not in contact with the frame.
z At the completion of operations, reconfirm correct connections and fastenings.
The positive terminal must be connected first in case of a removed battery.
Connected terminals must be coated with lubricant.
The terminals must be completely covered with caps.
z When a fuse is burnt, inspect the cause and replace the fuse with a fuse of equivalent
capacity.
z At the completion of operation, completely cover terminals with caps.
z When removing connectors with locks, they must be unlocked before operation.
When removing connectors, the connectors proper must be held instead of pulling their
wires.
11
z
z
r
te
C
en
pa
rts
e
ia
n
z
z
ar
z
z
Sp
z
an
z
z
pe
z
Before connecting connectors, confirm that they are free from breakage, bending, over
length or loosening.
Connectors must be inserted home.
When connecting connectors with locks, confirm that their locks are fastened.
Confirm that the wires are not loose.
Confirm that connectors’ plastic sleeves completely cover the connectors without fail.
Before connecting the connectors, confirm that their sleeves are free from breakage and
their terminals are not oversized.
Connector plugs must be fully inserted.
Confirm that plastic sleeves completely cover the terminals.
Plastic sleeves should not be placed with the open side up.
Wire bunch bands should be fixed at the specified position of motorcycle frame.
Wire clamps must correctly keep wires in place.
Avoid welding stains of welded clamps when clamping wires.
Wire bunches must be fixed away from turning or moving parts.
Do not damage the covering of wire bunches.
In case of wire bunch defects, remedy it with insulating bands.
Wire bunches must not be covered with mounted parts.
Do not twist or bend cables by force. Deformed or damaged cables would result in poor
rotation or damage.
Eu
ro
z
w
w
w
.a
si
am
ot
or
.s
e
Ba
ot
III. SPECIFIED TORQUES
Torques at important positions and standard torques of other positions are as follows:
12
SPECIFIED TORQUES
Frame:
Thread specification
Torques: N·m
Engine suspension lug mounting nut
1
M10
45
Engine mounting nut
1
M10
45
Front axle nut
1
M12
Rear axle nut
1
M16
Rear shock absorber upper mounting bolt
1
M10
40
Rear shock absorber lower mounting bolt
1
M10
25
Front shock absorber upper lock bolt
4
M8
Steering stem lock nut
1
Handlebar mounting nut
1
Upper bearing top
1
Designations
45
M25
2.5
M6
12
M8
35
Torques: N·m
5
ot
or
.s
e
Bolt, nut M5
Bolt, nut M6
10
Bolt, nutM8
21.5
35
Bolt, nut M12
55
Screw M5
4
w
.a
si
am
Bolt, nut M10
9
w
w
Screw M6
Flange bolt, nut M6
12
Flange bolt, nut M8
27
Flange bolt, nut M10
40
13
te
M10
ia
Ba
ot
Standard Torques:
C
en
pa
rts
70
ar
e
2
120
M25
n
Exhaust muffler mounting bolt
60
35
Sp
an
2
Eu
ro
Exhaust muffler connector nut
r
Number
pe
Designations of tightening positions
CHAPTER THREE
SECTION ONE
BODY TROUBLESHOOTING
BODY COMMON TROUBLES AND TROUBLE DETECTION
Body part common troubles and possible causes are as follows:
Handlebar rotation not
easy (strenuous turning
or unstable tightness)
Over tightening of handlebar adjusting nut
Eu
ro
pe
an
Sp
ar
e
pa
rts
Refer to “Handlebar
Service”, “Front Fork
Service”
Remarkable deformation of steering stem
due to outside impact
Over tightening of steering stem top ball
bearing retainer
Damaged or broken ball bearing
Reduced tire air
n
Imbalance of right and left shock absorbers
Refer to “Front Fork
Service”
Refer to “Front Wheel
Service”, “Rear Wheel
Service”
Refer to “Front Shock
Absorber Service”
Refer to “Front Fork
Service”
ia
Bent front fork
Ba
ot
Deflected steering stem
Refer to “Front Fork
Service”
Steering stem over worn
Incorrect mounting of brake cable or
tachometer cable
Heavy steering stem
turning
r
Details (reference)
te
Causes
C
en
Troubles
Refer to “Front Wheel
Service”
Bent front tire, deflected tire
ot
or
.s
e
Normal wear of brake lining
Hardened brake block or dusty block
Excessive front brake and rear brake
Damaged brake cable
Brake cam rotation not easy
Worn brake block
Worn or slotted brake drum bore
w
w
.a
si
am
Drum brake failure
Refer to “Brake System
Inspection, Adjustment
and Replacement”,
“Rear Brake Service”
w
Bent brake lever
Air in hydraulic device
Disk brake failure
Feeble brake
lever
Leakage in hydraulic
device
Clogged
passage
14
hydraulic
Refer to “Brake System
Inspection, Adjustment
and Replacement”,
“Front Brake Service”
Chart continued
te
C
en
Inadequate liquid
Contaminated
brake
block and brake disc
Bent or deformed brake
disc
Contaminated
brake
caliper
Worn seal ring of brake
caliper piston
Viscous or worn brake
caliper piston
Inability
of
brake
caliper normal sliding
Worn main cylinder
piston seal ring
Viscous or worn main
cylinder piston
Contaminated
main
cylinder
Clogged narrow brake
system
Clogged narrow liquid
passage
Viscous worn brake
caliper
Inability of brake
caliper normal sliding
Worn seal ring of brake
caliper piston
Viscous or worn main
cylinder piston
Contaminated brake
block and brake disc
Bent or deformed brake
disc
Inability of brake
caliper normal sliding
Wheel not adjusted
straight
Eu
ro
pe
an
Sp
ar
e
Feeble brake
lever
Details (reference)
r
Causes
pa
rts
Troubles
ot
or
.s
e
Ba
ot
ia
n
Disk brake failure
w
w
w
.a
si
am
Stiff brake lever
Resisted
braking
15
Refer to “Brake System
Inspection, Adjustment
and Replacement”,
“Front Brake Service”
Chart continued
Troubles
Causes
Details (reference)
Hardened brake block surface or dusty
block
Abnormal braking sound
Refer to “Rear Brake
Service”
Uneven or slotted brake block surface
te
r
Serious wear of brake block lining
C
en
Serious slots inside brake drum
Refer to “Front Fork
Service”
pa
rts
Steering stem rotation not easy
Bent shock absorber
Shock absorber oil leakage
incorrect
wheel
e
axle,
ar
Bent front
mounting
Sp
Deviation of motorcycle
direction (inclining to
roadside)
Refer to “Front Shock
Absorber Service”
Roundness error of wheel rim
an
Deformation of wheel rim
Refer to “Front Wheel
Service”
pe
Inadequate tire pressure
Eu
ro
Deformed wheel rim
Loose front wheel bearing
Poor tire
Refer to “Front Wheel
Service”
n
Front wheel oscillation
Ba
ot
ia
Poor axle locking
ot
or
.s
e
Soft front shock absorber
Rear wheel oscillation
Deformed wheel rim
Poor wheel
Refer to “Rear Wheel
Service”
Refer to “Rear Shock
Absorber Service”
Spring fatigue
w
w
w
.a
si
am
Soft rear shock absorber
Refer to “Front Shock
Absorber Service”
Spring fatigue
16
SECTION TWO DETAILED DESCRIPTION OF BODY PARTS TROUBLES
Precautions in Operation:
z
Forced mounting or dismounting of body cover parts will cause damage to claws and slots
of corresponding hoods.
When mounting body cover parts, be sure to align the corresponding parts of hoods.
When mounting body cover parts, avoid pressing wires, cables or pipes.
te
r
z
z
C
en
-
pa
rts
I. FRONT WHEEL SERVICE
Front Wheel Dismounting:
Support the body bottom to lift front wheel.
ar
front axle
e
front shock absorber
Sp
front axle nut
an
transmission gear box
small front axle bush
ot
or
.s
e
Remove front wheel.
Ba
ot
ia
n
Eu
ro
pe
Remove front axle nut, brake calipers, front
absorbers connecting bolt and remove brake
calipers, front shock absorber, transmission gear
box, front axle bush and the small bush, remove
front axle.
si
am
front axle bush
w
w
w
.a
Remove brake disc mounting bolts.
Remove brake disc.
bolt
brake disc
front shock absorber
17
brake caliper
front axle
mounting bolt
C
en
te
r
Axle Bending Inspection
Place axle on a V-seat and measure with a dial
gauge.
The dial gauge indicates a 1/2 bending value.
Limit of use: Replace if >0.2mm.
Eu
ro
pe
an
Sp
ar
e
pa
rts
Wheel Rim Oscillation Inspection
Measure oscillation value on a correcting bench.
Limit of use: Replace if >2.0mm.
Traverse direction: Replace if >2.0mm.
Front Wheel Bearing Inspection
Remove front wheel bearing and dust cover.
ot
or
.s
e
Ba
ot
ia
n
dust cover
w
w
.a
si
am
Turn bearing inner race to inspect sliding.
Replace it with a new one in case of no sliding or
damage or loosening of outer race.
w
front axle bush
Front Wheel Bearing Replacement
Dismounting: Remove front wheel bearing by
means of a bearing remover, take out spacer.
Mounting: Apply grease to the bearing.
Drive in left bearings.
18
C
en
te
r
Mount spacer.
Drive in right bearings.
z Bearings must be driven in parallel.
z Dust cover must be driven in with the face out.
Apply grease to new dust cover lip.
Mount front axle bush.
pe
an
Sp
ar
e
pa
rts
Front Wheel Mounting
Mount brake disc, tighten brake disc mounting bolts.
Torque: 27N·m
Spread front axle with a thin film of grease.
Mount front axle from left side.
Mount in order small bush, left front shock absorber, bush, front wheel, transmission gear box,
right front shock absorber, front axle nut and fasten it.
Torque: 60N·m
Mount brake caliper as specified.
Eu
ro
II. FRONT BRAKE SERVICE (DISK BRAKE)
Ba
ot
ia
n
Brake Oil Replacing
z Prevent dust or water from entering brake system.
z Do not use brake oils of different specifications or impure brake oils.
z Prevent brake oil from dripping onto rubber, plastic or painted parts.
oil reservoir cover
.a
si
am
ot
or
.s
e
Brake Oil Exhausting
Place main cylinder at a level place, remove oil
reservoir cover and diaphragm.
Connect a hose to oil exhaust valve, loosen
exhaust valve, grip and release brake lever till oil
is exhausted.
w
w
w
Brake Oil Replenishing
Lock exhaust valve.
Replenish oil reservoir with specified brake oil.
z It is not necessary to fill the oil reservoir
to its full capacity.
z Brake oil for replenishing should be the
same as original.
19
exhaust valve
gripping
C
en
releasing
pa
rts
brake lever
te
r
The specification of brake oil is indicated on the
reservoir cover.
Place diaphragm.
Connect a transparent hose to exhaust valve.
Grip brake lever fast and open exhaust valve 1/2
turn to let out air and lock exhaust valve. Repeat
this operation till no bubbles are exhausted from
brake oil passage.
z Do not release brake lever before exhaust
valve is closed.
Eu
ro
pe
an
Sp
ar
e
lower limit line
At the completion of adjustment, replenish brake
oil till oil is over the lower limit line of the oil
reservoir.
Mount diaphragm set and oil reservoir cover.
Tighten oil reservoir cover bolt.
head cover front part
head cover rear part
ot
or
.s
e
Ba
ot
ia
n
Main Brake Oil Tank Dismounting and Mounting
Dismounting
Remove 4 screws of front part and rear part of
head cover.
Remove front part and rear part of head cover.
si
am
screw
oil pipe bolt cylinder
brake
oil pipe
w
w
w
.a
Exhaust brake oil from front brake system.
Pull out brake switch plug from main cable.
Remove bracket bolts from handlebar;
Remove main cylinder.
Remove brake oil pipe from main cylinder.
z Prevent brake oil from splashing to
rubber, plastic or painted surfaces. Cover
the above-mentioned parts with a cloth.
20
bracket bolts
an
Sp
ar
e
Inspection
Inspect for wear or ageing of main and auxiliary cups on pistons.
Inspect for scratches and other damages on main cylinder and piston.
Measure main cylinder bore.
Measure outside diameter of piston at the end of auxiliary cup.
pa
rts
C
en
te
r
Remove brake light switch and brake lever.
Remove retaining ring from main cylinder.
z Use special retaining ring remover when
removing retaining ring.
Remove piston cover, piston and spring.
Clean oil reservoir and piston with pure
brake oil.
z Do not effect cleaning with gasoline as it
is corrosive to rubber parts.
ia
n
Eu
ro
pe
Mounting
Apply pure brake oil to piston, main cup and auxiliary cup.
Mount spring, piston, retaining ring and piston cap.
z Piston cup cannot be used inside out.
si
am
ot
or
.s
e
Ba
ot
Apply grease to brake lever axis pin.
Mount brake lever and brake switch.
Mount main cylinder, main cylinder bracket and lock them.
Mount brake oil pipe.
Connect brake light switch cable with switch.
Mount head cover front part and rear part.
Replenish brake oil and exhaust air in brake system.
.a
III. FRONT SHOCK ABSORBER SERVICE
w
w
w
Dismounting
Remove fender mounting bolt and front fender.
Remove front wheel.
bolt
front fender
front shock absorber
21
Remove 4 pieces of bolts on the upper part of
front shock absorber.
Remove shock absorber.
bolt
te
r
shock
absorber
pa
rts
e
ar
Sp
an
n
Eu
ro
pe
Mounting
Mount front shock absorber on front fork and
mount 4 bolts.
Torque: upper bolt 35N·m.
Mount front wheel.
Mount front fender.
C
en
Inspection
Inspect if there is oil leakage in front shock
absorber, if there is deformation of shock
absorber arm and if there is damage or loosening
of any part.
Ba
ot
ia
IV. FRONT FORK SERVICE
Dismounting
Remove motorcycle body covering parts.
ot
or
.s
e
bush
nut
bolt
.a
si
am
Remove handlebar bolt, bush and nut from
handlebar.
Remove handlebar.
handlebar
set nut steering stem
w
w
w
Remove steering stem setting nut.
Remove upper bearing cup, upper bearing top
and bearing set.
upper bearing
cup,bearing top
and ball set
22
Remove front wheel;
Remove front shock absorber, front fender
bracket, etc.
head tube
bottom bearing
cup,bearing top
and ball set
ar
e
pa
rts
C
en
te
r
front fender
bracket
shock
absorber
front wheel
Remove steering stem from head tube.
The removing of the bottom bearing cup, bearing
top and bearing set is the same as the removing
of the upper series.
z Do not damage steering stem when
removing bearing cup and bearing top.
z Clean opening parts of motorcycle body
covering parts with cloth.
an
pe
n
Eu
ro
Inspect for completeness of bearing balls and if
there is, effect replacement with new ones.
upper bearing top
Sp
Inspection
Inspect if there is slot or pit in bearing cup and
bearing top. If there is, effect replacement.
bottom bearing top
bottom bearing cup
ball set
ball set
Ba
ot
ia
Inspect for proper tightness of steering stem and
if not, effect adjustment and fasten it.
upper bearing cup
ot
or
.s
e
Inspect for correct position of bearing cup and bearing top and if not, effect correct mounting.
si
am
Bearing Cup and Bearing Top Replacement
Remove bearing cup and bearing top with special bearing cup and bearing top removers.
w
w
w
.a
Mounting
Apply grease to bearing cup and bearing top at the bottom.
Mount in order bottom bearing cup, bearing ball set, bottom bearing top on the bottom of
steering stem.
Pass steering stem through head tube.
Mount front fender bracket.
Mount front wheel.
Mount front shock absorber and other parts.
23
pa
rts
C
en
te
r
Apply grease to top bearing cup and bearing top.
Mount in order upper bearing cup, bearing ball set and upper bearing top on the upper part of
steering stem and fasten them.
Torque: 15 N·m
Turn front fork right and left to effect close contact of bearing balls.
Loosen upper bearing top to torque 0 and fasten it.
Torque: 2.5N·m
Fix upper bearing top and tighten steering stem setting nut.
Torque: 70N·m
Sp
ar
e
Turn front fork and confirm easy rotation without loosening.
Mount handlebar bolt, bush and nut from handlebar.
Mount handlebar.
pe
an
Mount front fender.
Mount motorcycle body covering parts.
left handlebar switch
handle bar
screw
left grip
ot
or
.s
e
Ba
ot
ia
n
Eu
ro
V. HANDLEBAR SERVICE
Dismounting
Remove covering parts of front part and rear part.
Remove connectors of left handlebar switch.
Remove 2 screws of left handlebar switch.
Remove left handlebar switch.
Remove left grip from handlebar.
left handlebar switch wire
right handlebar switch
throttle grip
screw handlebar
right handlebar
switch wire
w
w
w
.a
si
am
Remove front brake main cylinder.
Remove connectors of right handlebar switch.
Remove 2 screws of right handlebar switch.
Remove right handlebar switch.
Remove throttle cable from throttle grip.
Remove throttle grip from handlebar.
Remove handlebar bolt, bush and nut from handlebar.
Remove handlebar.
z When removing left handlebar and
throttle grip, remove contamination and
grease from contacting face.
24
throttle cable
Mounting
Mount handlebar on steering stem guide tube, fit
bush, setting bolt and nut.
Torque: 45 N·m
bush
nut
Mount left handlebar switch and fasten screws.
Torque: 9 N·m
C
en
te
r
bolt
Ba
ot
ia
VI. REAR WHEEL SERVICE
n
Eu
ro
pe
an
Sp
ar
e
pa
rts
Mount front brake main cylinder and fasten bolts.
Mount right handlebar switch and fasten screws.
Torque: 9 N·m
Apply grease to throttle cable.
Mount throttle grip and connect throttle cable.
Mount left grip.
Mount covering parts of front head cover and
rear head cover.
z Confirm easy rotation of throttle grip.
z When mounting handlebar rubber, apply a thin film of adhesive to contacting face and
then mount grip in a turning manner.
ot
or
.s
e
Dismounting
Remove 2 connecting nuts and 2 mounting bolts
of exhaust muffler.
si
am
Remove exhaust muffler.
Remove rear axle nut and rear axle.
.a
exhaust muffler
w
w
w
Rear Wheel Oscillation Inspection
Measure oscillation value on a correcting bench.
Limit of use: Longitudinal >2.0 mm
Traverse >2.0 mm
25
mounting bolts
connecting nuts
Mounting
Mount rear wheel and fasten rear axle nut.
Torque: 120N·m
Mount exhaust muffler.
Fasten exhaust muffler connecting nuts and bolts.
Torque:
Exhaust muffler connecting nut: 12N·m
Exhaust muffler mounting bolt: 35N·m
te
r
exhaust muffler
pa
rts
C
en
rear axle nut
ar
an
Sp
¦ µ
n
Eu
ro
pe
Remove exhaust muffler.
Remove rear wheel.
Inspect rear brake drum.
Measure rear brake drum bore.
Limit of use: Ø111mm, effect replacement if the
limit is exceeded.
e
VII. REAR BRAKE SERVICE
Ba
ot
ia
Rear Brake Block Replacement
Remove rear brake block and return spring as a
whole and replace them with new ones.
z See that no grease is with brake block
friction surface.
set pin
return spring
ot
or
.s
e
brake block
return spring
brake cam
si
am
brake block
w
w
w
.a
Rear Brake Disassembling
Remove rear brake adjusting nut, remove rear
brake cable from brake swing arm.
Remove brake block assembly.
Remove brake swing arm setting bolt and swing
arm.
Remove brake cam.
26
brake cam
set bolt
brake swing arm
rear brake cable
adjusting nut
pa
rts
C
en
Mount brake cam.
Mount brake swing arm on brake cam.
z Notch on brake swing arm should be aligned with the cut-off of brake cam.
te
r
Rear Brake Device Assembling
Apply grease to setting pin, brake cam and brake block friction surface.
Apply grease to moving part of brake cam.
z Do not apply grease to parts not specified. Superfluous grease flows into brake friction
linings of brake drum shall reduce braking effect.
ar
e
Mount brake swing arm setting bolt and fasten it.
Torque: 10N·m
an
Sp
Mount brake block assembled with spring.
Eu
ro
pe
Mount rear wheel.
Mount exhaust muffler.
ot
or
.s
e
Ba
ot
ia
n
Mount brake swing arm pin and rear brake cable.
z Mount return spring of brake cable with
the spring aligned with the recess hole of
left crankcase cover.
Mount adjusting nut.
w
w
w
.a
si
am
Adjust brake system.
27
adjusting nut
return spring
rear brake cable
VIII. REAR SHOCK ABSORBER SERVICE
te
r
Dismounting
Remove motorcycle body covering parts.
Remove 2 mounting bolts of air filter.
C
en
air filter
Remove mounting bolt connecting rear shock
absorber and motorcycle frame, bolt connecting
rear shock absorber and engine.
Withdraw air filter;
Remove rear shock absorber.
e
ar
Sp
an
pe
rear shock absorber
ia
n
Eu
ro
Inspection
Inspect rear shock absorber oil seal for oil
leakage, inspect buffer bar and spring for
deformation and other parts for damage and
loosening.
upper mounting
bolt
pa
rts
mounting bolts
Ba
ot
Mounting
Mount rear shock absorber.
Torque:
upper mounting bolt: 40N·m
bottom mounting bolt: 25N·m
Mount air filter.
Mount motorcycle body covering parts.
ot
or
.s
e
rear shock absorber
mounting bolt
w
w
w
.a
si
am
mounting nut
28